Mixed metal magnetic pulse impact beam

Abstract

An impact beam assembly includes a beam of high-strength steel, and a pair of end brackets constructed of a dissimilar material than the high-strength steel. The brackets are locally deformed onto the beam to thereby surround a portion of the beam. Once deformed, the brackets define a flat section suitable for welding to a vehicle door panel, as well as a section for retaining the beam. The beam can include a surface feature suitable for retaining the beam to the end brackets. A method of reinforcing a vehicle door assembly includes positioning the beam with respect to the end brackets such that the brackets surround a portion of the beam, and then activating a magnetic pulse coil (MPC) to deform an overlapping portion of the brackets onto the beam. The brackets are then attached to a surface of the door assembly to reinforce the door assembly.

Description

TECHNICAL FIELD[0001]The present invention relates generally to an impact beam for reinforcing a portion of a vehicle body, and more particularly to a high-strength mixed metal impact beam for reinforcing a vehicular door assembly or other vehicle body panel.BACKGROUND OF THE INVENTION[0002]In order to improve vehicle structural integrity, high-strength impact beams constructed of steel or other suitable impact-resistant material can be integrated into a vehicle body, for example by welding the impact beam into a door assembly. However, there is ordinarily a very limited amount of available space between an outer panel of the door assembly and any window glass and any internal mechanisms of the door assembly when the window glass is in a dropped position. As a result, there are limited options for integrating an impact beam within a vehicle door assembly, as well as a limited number of useful configurations of the impact beam itself.[0003]Additionally, in order to achieve ever incre...

AI Technical Summary

Benefits of technology

[0004]Accordingly, a method is provided that allows high-strength impact beams to be integrated into a low-mass vehicle body panel, such as but not limited to a door assembly or another closure panel assembly. The low-mass vehicle panel can be constructed of aluminum, magnesium, composite materials, and / or other relatively lightweight or low-mass materials in order to reduce the overall weight and mass of the vehicle. The combination of an impact beam constructed in accordance with the invention with a low-mass vehicular panel assembly provides a low-mass design with optimal structural integrity. Additionally, the formation method utilizes a mechanical deformation or fastening technique to form an mechanical interlock between different components of the impact beam assembly, and as a result provides a relatively low cost solution.

[0006]Additionally, an impact beam assembly for reinforcing a vehicle panel, such as but not limited to a vehicle door assembly, includes a pair of end brackets, as well as a beam constructed of high-strength steel. The end brackets are each configured for receiving a different end of the beam. To further reduce weight and mass, and to facilitate joining of the brackets to the door assembly, the end brackets can be constructed of a material that is substantially the same as the door construction and dissimilar to that of the high-strength steel, e.g., aluminum, magnesium, and / or other suitable material. The end brackets are locally deformed onto the beam to thereby surround or circumscribe at least a portion of the beam. The end brackets each include a splayed portion defining a flat section suitably adapted for welding or fastening to a surface of the vehicle panel. The end brackets also define a section suitable for retaining the beam. The beam can optionally include a surface feature for further retaining the beam to the end brackets as set forth hereinbelow.

Problems solved by technology

However, there is ordinarily a very limited amount of available space between an outer panel of the door assembly and any window glass and any internal mechanisms of the door assembly when the window glass is in a dropped position.

As a result, there are limited options for integrating an impact beam within a vehicle door assembly, as well as a limited number of useful configurations of the impact beam itself.

While such light-weight materials are desirable from a vehicle mass reduction standpoint, packaging space limitations as noted above can limit the effectiveness of impact beams constructed from such materials, which often must be enlarged in order to provide strength that is equal to that of an impact beam constructed of a high-strength material such as steel.

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